US2009254171A1PendingUtilityA1

Enhanced property metal polymer composite

Assignee: TUNDRA COMPSITES LLCPriority: Nov 14, 2003Filed: Nov 24, 2008Published: Oct 8, 2009

Est. expiryNov 14, 2023(expired)· nominal 20-yr term from priority

Inventors:Kurt E. Heikkila

A61F 2/82Y10T428/256F42B 7/046B29L 2031/22A01K 95/005C08K 3/08F42B 12/745G21F 1/10F42B 12/74C08K 7/06

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Claims

Abstract

The invention relates to a metal polymer composite having properties that are enhanced or increased in the composite. Such properties include color, magnetism, thermal conductivity, electrical conductivity, density, improved malleability and ductility and thermoplastic or injection molding properties.

Claims

exact text as granted — not AI-modified

1 . A metal and polymer viscoelastic composite comprising:
(a) a metal particulate, the particulate having a particle size greater than about 10 microns, a particle size distribution such that there is an effective amount of particulate in the range of 10 to 70 microns and greater than 70 microns to form the composite and a circularity of greater than 13; and (b) a polymer phase; wherein the viscoelastic composite has a tensile elongation of about at least 5%.

2 . The composite of claim 1 wherein the viscoelastic composite has a tensile elongation of at least 100%.

3 . The viscoelastic composite of claim 1 wherein the composite has a tensile strength of at least 0.2 MPa and a thermoplastic shear of at least 5 sec −1 .

4 . The composite of claim 1 wherein the metal particulate comprises a metal particle having a particle size distribution ranging from about 10 to about 1000 microns.

5 . The composite of claim 1 wherein the metal particle comprises an alloy particle.

6 . The composite of claim 1 wherein the particulate comprises a bimetallic particle.

7 . The composite of claim 1 wherein the particulate comprises a tungsten carbide particle.

8 . The composite of claim 4 wherein the composite contains about at least 5 wt.-% of particulate in the range of about 10 to 70 microns and about at least 5 wt.-% of particulate in the range of about 70 to 250 microns.

9 . The composite of claim 8 wherein the particulate about at least 5 wt.-% of a particulate in the range of about 250 to 500.

10 . The composite of claim 1 wherein the polymer comprises a fluoropolymer.

11 . The composite of claim 1 wherein the composite comprises about 0.005 to 4 wt % of an interfacial modifier.

12 . The composite of claim 1 wherein the metal particle has an excluded volume of about 13 vol.-% to about 61 vol.-%.

13 . The composite of claim 1 wherein the metal particulate comprises zinc.

14 . The composite of claim 1 wherein the metal particulate comprises tin.

15 . The composite of claim 1 wherein the metal particulate comprises iron.

16 . The composite of claim 1 wherein the metal particulate comprises bismuth.

17 . The composite of claim 1 wherein the metal particulate comprises tungsten.

18 . A metal fluoropolymer viscoelastic composite comprising:
(a) a metal particulate, the particulate having a particle size greater than about 10 microns, a particle size distribution such that there is an effective amount of particulate in the range of 10 to 70 microns and greater than 70 microns to form the composite and a circularity of greater than 13; and (b) a fluoropolymer phase;
wherein the composite is free of an interfacial modifier and the viscoelastic composite has a tensile elongation of about at least 5%.

19 . The composite of claim 18 wherein the viscoelastic composite has a tensile elongation of at least 100%.

20 . The viscoelastic composite of claim 18 wherein the composite has a tensile strength of at least 0.2 MPa and thermoplastic shear of at least 5 sec −1 .

21 . The composite of claim 18 wherein the metal particulate comprises a metal particle having a particle size distribution ranging from about 10 to about 1000 microns.

22 . The composite of claim 18 wherein the metal particle comprises an alloy particle.

23 . The composite of claim 18 wherein the particulate comprises a bimetallic particle.

24 . The composite of claim 18 wherein the particulate comprises a tungsten carbide particle or a silicon carbide particle.

25 . The composite of claim 21 wherein the composite contains about at least 5 wt.-% of particulate in the range of about 10 to 70 microns and about at least 5 wt.-% of particulate in the range of about 70 to 250 microns.

26 . The composite of claim 25 wherein the particulate further comprises about at least 5 wt.-% of a particulate in the range of about 250 to 500.

27 . The composite of claim 18 wherein the fluoropolymer comprises a fluoropolymer elastomer.

28 . The composite of claim 18 wherein the composite comprises about 0.02 to 2 wt % of an interfacial modifier.

29 . The composite of claim 18 wherein the metal particle has an excluded volume of about 13% to about 61%.

30 . The composite of claim 18 wherein the metal particulate comprises zinc.

31 . The composite of claim 18 wherein the metal particulate comprises tin.

32 . The composite of claim 18 wherein the metal particulate comprises iron.

33 . The composite of claim 18 wherein the metal particulate comprises bismuth.

34 . The composite of claim 18 wherein the metal particulate comprises tungsten.

35 . A metal polymer composite comprising:
(a) a metal particulate, the metal having a density greater than about 13 gm-cm −3 and a particle size greater than about 10 microns; and (b) a polymer phase;
wherein the metal comprises a particle having a distribution of particle size, the polymer in sufficient amounts to occupy substantially the excluded volume of the particulate and the composite density is greater than about 11 gm-cm −3 .

36 . The composite of claim 35 wherein the metal particulate comprises a circularity of greater than 13 and a density greater than 12 gm-cm −3 .

37 . The composite of claim 35 wherein the composite density is greater than 16 gm-cm −3 .

38 . The composite of claim 35 wherein the polymer is a halogen containing polymer having a density of greater than 1.7 gm-cm −3 .

39 . The composite of claim 35 wherein the composite comprises an organic or inorganic pigment.

40 . The composite of claim 35 wherein the composite comprises an organic dye.

41 . The composite of claim 35 wherein the metal particulate comprises tungsten having a particle size distribution ranging from about 10 to 70 microns.

42 . The composite of claim 41 wherein the metal particulate comprises tungsten having at least 5 wt.-% with a particle size ranging from about 70 to 250 microns.

43 . The composite of claim 38 wherein the polymer comprises a fluoropolymer.

44 . The composite of claim 35 wherein the metal particulate has an excluded volume about 13 vol.-% to about 61 vol.-%.

45 . A metal polymer composite comprising a metal particulate in a polymer phase, the composite comprising:
(a) about 90 to 50 volume-% of a metal particulate, having a density greater than 13 gm-cm −3 and less than 23 gm-cm −3 , a particle size greater than 10 microns, at least 5 wt.-% of particulate having a particle size distribution of 10 to 70 microns a circularity greater than 13 and an aspect ratio less than 3; (b) about 10 to 50 volume-% of a polymer phase; and (c) about 0.005 to 2 wt.-% of an interfacial modifier material;
wherein the composite density is greater than about 11 gm-cm −3 .

46 . The composite of claims 45 wherein the metal particulate comprises at least about 5 wt.-% of particulate in the range of about 70 to 250 microns.

47 . The composite of claims 45 wherein the composite comprises polymer blend or alloy and the interfacial modifier comprises about 0.005 to 1 wt.-% of the composite.

48 . The composite of claims 45 wherein the metal particulate comprises tungsten.

49 . The composite of claim 45 wherein the metal particulate is present in an amount of about 50 to 85 volume-% and the circularity is about 14 to 20.

50 . The composite of claim 45 wherein the polymer is a halogen containing polymer having a density of greater than 1.7 grams-cm −3 .

51 . The composite of claim 45 wherein the composite comprises an organic or inorganic pigment.

52 . The composite of claim 45 wherein the composite comprises an organic fluorescent dye.

53 . The composite of claim 45 wherein the metal has a density greater than 13 gm-cm −3 .

54 . A metal polymer composite comprising a metal particulate in a polymer phase, the composite comprising:
(a) about 50 to 90 volume-% of a metal particulate having a density greater than 13 gm-cm −3 , the particulate comprising at least about 5 wt.-% having a particle size about 10 to 70 microns, at least about 5 wt.-% having a particle size about 70 to 250 microns and a circularity about 13 to 20; (b) about 50 to 10 volume-% of a polymer phase; and (c) about 0.005 to 2 volume-% of an interfacial modifier;
wherein the composite density is greater than about 11 gm-cm −3 .

55 . The composite of claim 54 wherein the interfacial modifier comprises an organic aluminate, an organic zirconate, an organic titanate, an organic silicate or mixtures thereof.

56 . The composite of claims 54 wherein the metal comprises tungsten and the polymer comprises a vinyl polymer.

57 . The composite of claim 54 wherein the metal particulate is present in an amount of about 75 to 85 volume-%.

58 . The composite of claim 54 wherein the polymer is a halogen containing polymer having a density of greater than 1.7 gm-cm −3 .

59 . The composite of claim 54 wherein the composite comprises an organic or inorganic pigment.

60 . The composite of claim 54 wherein the composite comprises an organic fluorescent dye.

61 . The composite of claim 54 wherein the metal has a density greater than 13.2 gm-cm −3 .

62 . A metal polymer composite comprising a metal particulate in a polymer phase, the composite comprising:
(a) about 50 to 90 volume-% of a metal particulate having a density greater than 11 gm-cm −3 , the particulate comprising at least about 5 wt.-% having a particle size about 10 to 70 microns, at least about 5 wt.-% having a particle size about 70 to 250 microns and a circularity about 14 to 20; (b) a fluoropolymer elastomer phase;
wherein the composite density is greater than about 11 gm-cm −3 .

63 . The composite of claims 62 wherein the composite comprises a metal oxide interfacial modified material.

64 . The composite of claim 62 wherein the interfacial modifier comprises a zirconate.

65 . The composite of claims 62 wherein the fluoropolymer comprises an elastomer with a density greater than 1.7 gm-cm −3 .

66 . The composite of claims 62 wherein the metal particulate comprises tungsten

67 . The composite of claim 62 wherein the metal has a density greater than 11 gm-cm −3 and is present in an amount of about 80 to 90 volume-%.

68 . The composite of claim 62 wherein the composite comprises an inorganic pigment.

69 . The composite of claim 62 wherein the composite comprises an organic fluorescent dye.

70 . A vascular stent comprising the composite of claim 1 .

71 . A vascular stent comprising the composite of claim 35 .

72 . A shotgun shot comprising the composite of claim 1 .

73 . The shot of claim 72 comprising molded dimples on the shot to reduce the drag and improve the flight during the travel of the shot.

74 . A shotgun shot comprising the composite of claim 35 .

75 . The shot of claim 74 comprising molded dimples on the shot to reduce the drag and improve the flight during the travel of the shot.

76 . A shotgun shot comprising the composite of claim 18 .

77 . The shot of claim 76 comprising molded dimples on the shot to reduce the drag and improve the flight during the travel of the shot.

78 . A projectile comprising the composite of claim 1 .

79 . The projectile of claim 78 comprising a metal jacket.

80 . The projectile of claim 78 wherein the jacket has a tapered leading end and an open following end.

81 . A projectile comprising the composite of claim 35 .

82 . The projectile of claim 81 comprising a metal jacket.

83 . The projectile of claim 82 wherein the jacket has a tapered leading end and an open following end.

84 . A projectile comprising the composite of claim 35 .

85 . The projectile of claim 84 comprising a metal jacket.

86 . The projectile of claim 85 wherein the jacket has a tapered leading end and an open following end.

87 . A fishing jig comprising a hook and a sinker portion comprising the composite of claim 1 .

88 . A fishing jig comprising a hook and a sinker portion comprising the composite of claim 35 .

89 . The jig of claim 87 wherein the sinker is snap fit onto the hook.

90 . The jig of claim 87 wherein the sinker is compression molded onto the hook.

91 . A weight comprising attachment means and a article comprising the composite of claim 1 .

92 . The weight of claim 91 wherein the attachment means is a clip.

93 . The weight of claim 91 wherein the attachment means is an adhesive layer.

94 . A metal particle-polymer composite comprising a metal particulate having a range of particle sizes such that about at least 5 wt.-% of particulate in the range of about 10 to 70 microns and about at least 5 wt.-% of particulate in the range of about 70 to 250 microns, and a polymer, the composite having a van der Waals&#39; dispersion bond strength between molecules in adjacent particles of less than about 4 kJ-mol −1 and a bond dimension of 1.4 to 1.9 Å.

95 . The composite of claim 1 wherein the van der Waals&#39; dispersion bond strength between molecules in adjacent particles of less than about 2 kJ-mol −1 and the van der Waals&#39; bond dimension is about 1.5 to 1.8 Å.

96 . The composite of claim 91 , comprising an automotive wheel weight, crankshaft weight, driveshaft weight, or an aircraft ballast weight.

97 . A battery comprising of the composite of claim 1 .

98 . A semiconductor comprising of the composite of claim 1 .

99 . A nuclear fuel rod comprising of the composite of claim 1 .

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